USERS MANUAL Heavy duty slurry pumps TOYO PUMPS EUROPE Edition 27.07.2007
SAFETY INSTRUCTIONS TOYO PUMPS EUROPE
Users manual for Toyo pumps type «DP..-6 30~40HP» This users manual will help you to maintain your Toyo pump in optimum working condition for a long time. Please read carefully before using the pump and keep for future reference. Take note of the serial number which you can find on the identification plate of your pump. The manufacturer reserves the right to modify specifications and concept of these products without previous notice. Edition 27.04.2007 TOYO PUMPS EUROPE Parc Industriel Sud Zone II Rue de l Industrie, 41 1400 Nivelles Belgique Tel.: (32) 67.64.55.37 Fax. : (32) 67.64.55.31 E-mail : info@toyopumpseurope.com Web site : www.toyopumpseurope.com TOYO PUMPS EUROPE
CONTENTS Introduction 1 Precautions before operating 1 Notes on driving 2 Maintenance and troubleshooting 3 Points to be attentive 4 Troubleshooting list 5 Disassembling procedures 7 Assembling procedures 9 Technical specifications 11 Pump performance curve 12 Dimensions 13 Spare parts list 14 Exploded view drawings 19 TOYO PUMPS EUROPE
INTRODUCTION A wrong utilisation and an inadequate manipulation of the pump will cause unsatisfactory performances and early troubles. Therefore, please read this instruction manual carefully before operating. PRECAUTIONS BEFORE OPERATING 1. Power supply Check the power supply voltage and frequency by referring to the identification plate on the pump. Operation of the pump on a different power voltage from the specified voltage will cause impossibility of pumping up and motor burning. 2. Grounding Make sure to connect the pump correctly to the earth. The earth-cable is the green and yellow coloured one. 3. Rotation direction As to the rotating direction, counterclockwise rotation viewing from the suction intake side (lower side of the pump) is the correct way of rotating. The rotation direction is mentioned on the identification plate of the pump. After connecting the pump, let it turn out of the liquid to be pumped for an instant, in order to check the direction of the motor by observing the agitator. Attention, the agitator could detach itself when turning in opposite direction. You only need to invert two of the three alimentation wires whenever the electric motor turns in the wrong direction. Rotation without being submerged for a longer period of time causes damages to the seals. The rotating direction of the agitator can be verified instantaneously. Never drive the pump in opposite direction, as this causes early damages to the pump. 4. Protection of electric motor In any case, it is necessary to protect the pump with a correctly calibrated thermal protection to avoid any overload and to install a start-stop switch. Pumps going up from 15 HP and more will have to be set up with a reactor starter box. The supplier of the pump can advise you the adequate material. TOYO PUMPS EUROPE - 1 -
5. Cabtyre cable a) The use of a cabtyre cable which has an inferior section or a superior length then recommended can make the starting up of the pump impossible and provoke damages to the motor. Concerning the characteristics of the cable to use, please refer to the technical characteristics of the pump. b) To avoid tearing out the cable, make sure that the length of the alimentation cable corresponds to the depth at which the pump will have to work. When lengthening the cable, which is fixed to the pump with a second cable, you should make sure not to submerge their connection. 6. Discharge hose The diameter of the discharge hose fixed to the pump has to be adapted to the diameter of the hose nipple of the pump. The discharge hose will preferably be fixed with half-circular collars. NOTES ON DRIVING a) For your safety, never touch the agitator when the pump is connected, and never pass underneath the pump while it is suspended. b) When the pump is in duty, it has to be immersed until the level indicated on the schema representing the dimensions of the pump. c) If possible, avoid using the pump in conditions that provoke an overload. See in particular to immerse the pump progressively until the material to pump is reached. d) Inspect the good working condition of the pump by securing that the intensity of the current does not exceed the value indicated on the identification plate of the pump. e) Avoid suspending the pump (vertical models) in such way that it might get buried at the bottom. f) Once the level of the pumped liquid becomes insufficient, noisy functioning and abnormal wear are generated. In this case, add liquid or stop the pump and wait for the liquid to rise. g) Despite the effect of the agitator, oversized materials, such as pieces of wood, etc. have the propensity to present themselves at the entrance of the pump. Therefore the pump has to be equipped with iron bars permitting objects of the same dimension as the holes of the strainer. Consult your supplier. TOYO PUMPS EUROPE - 2 -
h) The density of the pumped liquid can be verified by raising or descending the pump. A to heavy density can provoke the blockage of the discharge hose and of the pump and make pumping impossible. Heavy densities have to be avoided. i) Use a sufficient resistant chain, which will be attached to the lifting eyes provided on the pump for transporting or handling the pump. The angle between the two parts of the chain may not overshoot 60 degrees. j) Never suspend the pump by its alimentation cable. k) Rinse the pump and the discharge hose with clean water before turning it off. MAINTENANCE AND TROUBLESHOOTING a) Measure periodically the voltage of the alimentation current to verify that the pump works at the correct voltage. b) The insulation resistance of the motor has to be verified at least once a month. If the resistance of the motor is inferior to 100M Ohm, the winding of the electric motor has to be dried and the tightness of the cables checked, etc. c) The oil capacity in the under cover has to be verified every 500 hours. Therefore, place the pump horizontally (vertical pumps). If needed, add oil as specified in the table of technical characteristics of the pump (normal or biodegrading) through the opening provided to this end. d) If the presence of water in the oil is established (whitish emulsion), or if the oil contains solid particles (mud, etc.), it means that the seals are defective. Their replacement is then required. e) The quantity of oil in the under cover of the pump is specified in the technical specifications of the pump. f) If the flow of the pump is diminishing, the space between the impeller disc and the impeller has to be checked. The recommended space is indicated in the technical specifications of the pump. TOYO PUMPS EUROPE - 3 -
POINTS TO BE ATTENTIVE a) The maximum liquid temperature for the standard versions is 60 C. b) Avoid that pumped materials (ex. mud, ) are sticked on the motor part of the pump. This can provoke an abnormal heating of the motor. Clean the pump if this occurs. c) If air occurs in the discharge hose, it happens that the liquid can not be pumped any more. In that case, verify if the discharge hose is placed as horizontal as possible (ex. avoid to large space between the floaters). TOYO PUMPS EUROPE - 4 -
TROUBLESHOOTING LIST The pump is in duty but doesn t turn even as the switch is in ON position. The pump emits no sound : - Electric alimentation problem: Verify if the network is under tension and/or the generator works properly. - Defective connection or breakdown of one of the alimentation wires: Verify all connections and check the state of the wires. - Alimentation throw one single phase : Verify the connections and fuses. The pump emits a sound : - A foreign body blocs the agitator or is jammed between impeller and impeller disc : Remove the foreign body. - The impeller disc is blocked against the impeller : Adjust the space between the two parts as indicated in the technical characteristics. - A bearing is broken : Replace the bearing. - Wire breakdown in one of the wires inside the winding of the stator : Consult your supplier. - The stator is burned : Consult your supplier. The pump turns when the switch is in ON position but The pump emits an abnormal sound : - A foreign body blocs the agitator or is jammed between impeller and impeller disc : Remove the foreign body. - The impeller disc is in contact with the impeller : Adjust the space between the two parts as indicated in the technical characteristics. - Defective bearing : Replace the bearing. TOYO PUMPS EUROPE - 5 -
The flow of the pump is to weak : - The pump turns in the opposite direction : Inverse two of the three alimentation phases. - The level of the pumped liquid is insufficient : Add to the level. - Obstruction at the entrance of the pump or at the discharge hose : Verify and clean up. - Air in the discharge hose : Place the hose as horizontal as possible. - Wear of the impeller and the impeller disc : Adjust the space between the two parts as indicated in the technical characteristics. - The pump provided to work in 60 Hz is furnished in 50 Hz : Consult your supplier. - Insufficient discharge pressure : Consult your supplier. The thermal protection disconnects : - The density of the pumped liquid is to important : Lower the density by lifting the pump and/or by diluing the pumped materials. - Important voltage drop : Replace the alimentation cable by a cable with correct section and length as indicated in the technical specification of the pump. - The impeller disc is in contact with the impeller : Adjust the space between the two parts as indicated in the technical characteristics. - One of the phases is missing : Complete inspection out of the liquid of the electric circuit going from the source untill the electric motor. - The pump provided to work in 50 Hz is furnished in 60 Hz : Consult your supplier. - The electric motor is burned : Consult your supplier. TOYO PUMPS EUROPE - 6 -
DISASSEMBLING PROCEDURES Choose a dry and clean place to dismantle and reassemble your pump and install a base on which you can put the pump. It is also wise to prepare a few small boxes in which you can put the small parts dismantled from the pump. Prepare also some rags, oil and tools. The numbers mentioned between parenthesises in the description correspond to the parts numbers in the spare parts list. 1. Disassembling of the electric cable a) Unscrew the cap nuts (1C) en remove the lead cover (8). b) Disconnect the electric cable (7A) of the terminal board (99A) and remove the packing (2). c) In case you want to dismantle the motor case (28), you need, at this stage, also to disconnect from the terminal board (99A) the wires coming out from the electric motor. d) If you wish to replace the electric cable (7A), unscrew the cap nuts (106C) and release the packing gland (3) with the cable protection tube (6), the packing set ring (5) and the packings (4). 2. Disassembling of the pump section a) Place the pump horizontally and fix it in such way that it can not move during the disassembling procedure. b) The cutter fan (81) is screwed (normal right thread) on the shaft (29). To dismantle the cutter fan, hit it with a mallet or hammer, by interposing a bronze or aluminium jig, on one of the corners of the cutter fan. Unscrew it in counterclockwise direction, the pump seen from beneath (aspiration side). c) Unscrew the set bolts (79A) and remove the strainer (80). d) Unscrew the cap nuts (69C) and remove the suction cover (74) together with the impeller disc (73) with the adjust bolts (69D). Remove the packing (77) and clean carefully its location in the vortex casing. e) Separate the suction cover (74) from the impeller disc (73) by unscrewing the cap nuts (76C) using the adjust bolts (85). f) Unscrew the impeller nuts (83). Remove the impeller collar (82), the impeller (72). g) Unscrew the cap nuts (69C) and remove the vortex casing (56). Take care not to damage the threat of the shaft (29). Remove the packing (68) and the key (55). h) Unscrew the cap nuts (67C) and remove the delivery cover (71). Take care not to damage the threat of the stud bolts (67A). TOYO PUMPS EUROPE - 7 -
3. Disassembling of the shaft sealed section a) Unscrew the set bolts (21) and remove the oil inlet covers (66) from the opening in the under cover (37). Collect the lubrication oil in a recipient. Remove the packings (65). b) Unscrew the bolts (35A) and remove the oil seal housing B (61) using the adjust bolts (35C). Remove the packing (62). c) Remove the distance sleeve (54) and the O Ring (53). Remove the shaft sleeve B (51) and the bearing lock plate B (48). d) Unscrew the set bolts (64A) and pull out the oil chamber cover (60) with the adjust bolts (64C). Remove the packing (63). e) For taking out the bearing (47), unscrew the set bolts (59A), remove the bearing set plate (46), and then extract the bearing by pressure. f) Remove the bearing sleeve (45) and unscrew the set bolts (35A) to extract the oil seal housing A (58). Remove the packing (57). g) Remove the O Ring (40) and the shaft sleeve A (44). h) Remove the oil seals (41)(49), the Rareflon seals (43)(52) and the space rings (42)(50) from the housings (58)(61). 4. Disassembling of the motor section a) Set up the pump up side down, posed on the upper cover. b) Unscrew the bottom cap nuts (32C) of the motor case (28). c) Lift up the under cover (37) rotor (30) and shaft (29) assembly using a lifting device. Separate them from the motor case (28) with help of the adjust bolts (32D). d) Unscrew the set bolts (35A) of the bearing cover (34). e) Separate shaft (29) and rotor (30) from the under cover (37) using a lifting device. f) Lay down the shaft (29) with rotor (30) horizontally and pull out the bearings (38)(39) and the internal bush of the bearing (23) with help of an appropriated extractor. g) The wires coming out of the stator has to be preliminary disconnected of the terminal board of the pump (see 1c) and then unscrew the upper cap nuts (32C) of the motor case (28). Separate the motor case (28) with stator (31) from the upper cover (16) of the pump. Remove the packing (19). h) If necessary, pull out the bearing cover A (26) and the external bush of the bearing (23) from the upper cover (16). TOYO PUMPS EUROPE - 8 -
The disassembling of the pump is now finished. Take care to clean all parts before reassembling them. ASSEMBLING PROCEDURES To reassemble the pump, it is sufficient to follow the disassembling procedures in opposite direction. Please find here below the specific assembling instructions. 1. Bearings a) The bearings may be mounted by pression exerted on the internal ring of the bearing by the instrumentality of a jig. Do not forget to grease the shaft and the internal ring of the bearing before mounting. b) Nevertheless, it is recommended to heat the bearings before mounting. In this case, heat up the bearings by induction or in oil at maximum 120 C and slide them on the shaft. Afterwards, let the bearings cool down by air. c) Use only grease for bearing lubrication or lithium grease. 2. Seals in under cover a) Verify the condition of the shaft sleeves A and B (44)(51) and the oil seal housing A and B (58)(61) before beginning the assembly of the pump. Replace the shaft sleeves if the surface is used, grooved, or even showing the base metal. Their surface needs to be rigorously smooth to assure the tightness. All seals into the under cover have to be replaced. b) Attention, the seals have to be mounted so that the opening of the seal is showing the bottom of the oil seal housing (impeller side). The oil seals will be completely filled up with water-resistant grease before mounting into the oil seal housing. Put the oil and Rareflon seals into the oil seal housing (58)-(61), and this in the same order as shown on the exploded view. For this, use a hammer and a jig (schema 1). Never use a hydraulic system. Proceed with care by exercising the most uniform pressure as possible. A deformed seal looses its efficiency. No trace of paint at all may be found on the oil seal. TOYO PUMPS EUROPE - 9 -
3. Other seals Renew all seals after disassembling. 4. Clearance between impeller and impeller disc Unscrew the cap nuts (76C). Push the impeller disc (73) against the impeller (72) with the adjust bolts (85). Unscrew the adjust bolts (85) with half a turn. Fasten the cap nuts (76C) and the adjust bolts (85). Measure the clearance between the impeller disc and the impeller. This clearance has to be between 1.0 and 1.5 mm. Verify the clearance with a gauge. Turn the shaft of the pump by hand. No friction is admitted at all. If necessary, repeat the operation. 5. Electric connection Connect the pump as shown on the drawing here below. N.B. : Do not forget to fill up the under cover with oil. Therefore, use the opening into the under cover. Type and oil quantity is mentioned in the technical specifications sheet of the pump. TOYO PUMPS EUROPE - 10 -